Featured Tesla Aluminum Battery Chemistry

Discussion in 'Prius, Hybrid, EV and Alt-Fuel News' started by bwilson4web, Oct 28, 2025 at 4:06 AM.

  1. bwilson4web

    bwilson4web BMW i3 and Model 3

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    Google tells me:

    No credible evidence suggests Elon Musk has touted a specific aluminum battery chemistry or that Tesla is planning to commercialize one in the near future. The widespread rumors originate from unverified YouTube videos and blogs that combine speculation with sensationalized headlines.
    What is known about aluminum battery rumors
    Rumor mill, not official channels.

    Claims about a "game-changing" aluminum-ion or aluminum-air battery for an upcoming Tesla Model 2 appear almost exclusively in unofficial media. Reputable fact-checking sites found no official confirmation from either Tesla or Musk.

    Tesla's focus remains lithium-ion. The company's confirmed battery development is focused on improving its existing lithium-ion technology, specifically the 4680 cell, and securing the supply chain for materials.

    Conflated with other company's work. Some reports may be confused with the work of other companies, such as Graphene Manufacturing Group (GMG), which is developing graphene aluminum-ion batteries that are not associated with Tesla.

    The allure of aluminum-ion. Rechargeable aluminum-ion batteries are a real field of research, separate from Tesla. Researchers are exploring them for potential benefits like low cost, reduced flammability, and high capacity. However, they face significant technical challenges that prevent their mass-market adoption.

    "Aluminum" batteries in existing Teslas. Tesla's premium vehicles already use a Nickel-Cobalt-Aluminum (NCA) cathode chemistry, but this is a standard form of lithium-ion battery technology, not the rumored aluminum-ion or aluminum-air battery.

    Why are aluminum battery claims so persistent?
    The persistent circulation of these rumors is largely driven by a combination of factors:
    Clickbait sensationalism: Claims of a revolutionary, "lithium-killing" battery are powerful clickbait and generate significant online traffic.
    Plausible speculation: As aluminum-ion battery research is a legitimate field, it provides a plausible-sounding basis for speculation. The element's high abundance and recyclability also make for a compelling narrative.
    Ambiguity and hype: Some creators of these videos openly admit to mixing fact with speculation and creative interpretation, leading to a confusing blend of credible research and baseless     ​

    There are aluminum primary batteries used on salt water craft. The sacrificial aluminum goes away while providing a protective voltage so other, less reactive metals are not corroded. Metallic aluminum has a high energy content used for rock engines and thermite. But this remains a one-way trip as converting the reacted aluminum by-products task special, reactive cells.

    Metal-air batteries are primary cells, discharge only. But if a swappable battery pack existed that retained the expired by-products, they might make a reasonable EV system. The high energy content would work for aviation with the conformal, structural battery packs being swapped on the ground. It would be a nice solution for very large, multi-ton, vehicles.

    I had once thought about an iron-air battery that would release the rust on the road. A fairly benign compound, it would 'gravity collect' in culverts, streams, creeks, and rivers in a form that might be economical to harvest and recycle.

    Bob Wilson
     
    #1 bwilson4web, Oct 28, 2025 at 4:06 AM
  2. Trollbait

    Trollbait It's a D&D thing

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    Phinergy's plan was for their Al-air battery to be used as a range extender. The metal plates would need to be replaced, and reacted aluminum reclaimed. Dumping any particles will lead to public health and environmental issues.
     
    #2 Trollbait, Oct 28, 2025 at 10:03 AM
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  3. drash

    drash Senior Member

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    Yeah we talked about this around 2013 - 2014 time range. It is very close to being a flow battery but that definition is arguable. I think what they are talking about is an Aluminum-ion (or aluminum rich) battery where the battery would have aluminum added to the cathode of a Lithium-ion battery. Google says:

    "Advantages
    • Higher energy density:
      Aluminum ions can transfer more electrons than lithium ions, potentially leading to much higher energy density and smaller, lighter batteries.
    • Improved safety:
      Aluminum is non-toxic and non-flammable, which reduces fire and explosion risks compared to lithium-ion batteries. Aluminum-ion batteries are also less prone to dendrite formation, a common problem that can cause short circuits in lithium-ion batteries.
    • Lower cost and abundance:
      Aluminum is much more abundant and cheaper than lithium, which could significantly lower battery production costs.
    • Faster charging:
      Some aluminum-ion battery designs have demonstrated the ability to charge much faster than traditional lithium-ion batteries.
    Challenges
    • Lower theoretical voltage:
      The theoretical voltage for an aluminum-ion battery is currently lower than for a lithium-ion battery, which is a significant hurdle for its development.
    • Electrode and electrolyte issues:
      Research is ongoing to improve the capacity, reaction kinetics, and cycling stability of the cathode and anode materials.
    • Commercial viability:
      Despite significant progress, aluminum-ion batteries still face challenges in achieving commercial viability and large-scale production."
    This is similar to Toyota's R&D on Manganese rich Lithium-ion battery for their NMC battery cells to replace more cobalt.
     
    #3 drash, Oct 29, 2025 at 11:54 AM
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  4. drash

    drash Senior Member

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    So Google says the cathode is being enhanced when other sites show the Anode being used as in this picture:
    88055_aluminium-ion-battery-nature-1_630m.jpg
     
    #4 drash, Oct 29, 2025 at 12:02 PM
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  5. bwilson4web

    bwilson4web BMW i3 and Model 3

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    I go by high school chemistry: Galvanic Corrosion vs. Electrode Potential

    upload_2025-10-29_23-54-7.png
    . . .
    upload_2025-10-29_23-55-21.png

    Missing from table:
    Carbon -0,207 V
    Oxygen +1.23 V​

    The highest voltage cell would react the top and bottom elements:

    Fluorine (+2.87) - Litium (-3.04) ~= 5.91 V :: However manufacturing is non-trivial engineering task​

    Bob Wilson
     
    #5 bwilson4web, Oct 30, 2025 at 1:07 AM
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